The present disclosure describes optoelectronic modules (e.g., hybrid lens array packages) that have multiple optical channels, each of which includes at least one beam shaping element (e.g., a lens) that is part of a laterally contiguous array. Each optical channel is associated with a respective light sensitive region of an image sensor. Some or all of the channels also can include at least one beam shaping element (e.g., a lens) that is not part of a laterally contiguous array. In some cases, the arrays can include alignment features to facilitate alignment of the arrays with one another.
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1. An optoelectronic module having a plurality of optical channels, the module comprising:
an image sensor including light sensitive regions each of which is associated with a respective one of the optical channels;
a first laterally contiguous array of first beam shaping elements, each of which is associated with a different respective one of the optical channels;
a second laterally contiguous array of beam shaping elements, wherein the second laterally contiguous array is of a type different from the first laterally contiguous array; and
one or more second beam shaping elements that are not part of a laterally contiguous array spanning more than one of the optical channels, wherein each of the one or more second beam shaping elements is associated with a respective one of the optical channels,
wherein one of the first or second laterally contiguous arrays includes multiple beam shaping elements formed together with a common body portion as a single monolithic piece and another of the first or second laterally contiguous arrays includes replicated beam shaping elements on a common transparent substrate.
16. An optoelectronic module having a plurality of optical channels, the module comprising: an image sensor including light sensitive regions each of which is associated with a respective one of the optical channels; a first laterally contiguous array of first beam shaping elements, each of which is associated with a different respective one of the optical channels; a second laterally contiguous array of beam shaping elements, wherein the second laterally contiguous array is of a type different from the first laterally contiguous array; and a plurality of second beam shaping elements that are not part of a laterally contiguous array spanning more than one of the optical channels, wherein each of the second beam shaping elements is disposed on a same side of the first array of beam shaping elements as the other second beam shaping elements and is associated with a respective one of the optical channels, wherein at least some of the second beam shaping elements are substantially not co-planar with one another; wherein one of the first or second laterally contiguous arrays includes multiple beam shaping elements formed together with a common body portion as a single monolithic piece and another of the first or second laterally contiguous arrays includes replicated beam shaping elements on a common transparent substrate.
15. An optoelectronic module having a plurality of optical channels, the module comprising: an image sensor including light sensitive regions each of which is associated with a respective one of the optical channels; a first laterally contiguous array of first beam shaping elements, each of which is associated with a different respective one of the optical channels; a second laterally contiguous array of beam shaping elements, wherein the second laterally contiguous array is of a type different from the first laterally contiguous array; and one or more second beam shaping elements that are not part of a laterally contiguous array spanning more than one of the optical channels, wherein each of the one or more second beam shaping elements is associated with a respective one of the optical channels, wherein the first laterally contiguous array of beam shaping elements is disposed in a first lens barrel, and each of the one or more second beam shaping elements is disposed in a respective second lens barrel different from the first lens barrel, and wherein one of the first or second laterally contiguous arrays includes multiple beam shaping elements formed together with a common body portion as a single monolithic piece and another of the first or second laterally contiguous arrays includes replicated beam shaping elements on a common transparent substrate.
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This disclosure relates to optoelectronic modules including hybrid arrangements of beam shaping elements, and imaging devices incorporating the same.
Optical imaging devices, such as multi-channel or array cameras, sometimes employ lenses stacked along the device's optical axis in order to achieve desired performance. Various problems with the lenses, however, can adversely impact the performance in such imaging applications. For example, some lens arrangements result in poor or sub-par alignment or may have relatively large manufacturing tolerances. Some manufacturing techniques may produce significant dimensional variations in the lenses. Further, in many consumer electronics and other applications, space is at premium. Thus, it often is desirable to reduce the overall footprint of the lens array package.
The present disclosure describes optoelectronic modules (e.g., hybrid lens array packages) that have multiple optical channels, some or all of which include at least one beam shaping element (e.g., a lens) that is part of a laterally contiguous array. Each optical channel is associated with a respective light sensitive region of an image sensor. Some or all of the channels also can include at least one beam shaping element (e.g., a lens) that is not part of a laterally contiguous array that spans more than one optical channel.
For example, in one aspect, an optoelectronic module has a plurality of optical channels. The module includes an image sensor including light sensitive regions each of which is associated with a respective one of the optical channels. The module further includes a first laterally contiguous array of first beam shaping elements, each of which is associated with a different respective one of the optical channels. The module also includes one or more second beam shaping elements that are not part of a laterally contiguous array spanning more than one of the optical channels. Each of the one or more second beam shaping elements is associated with a respective one of the optical channels.
In some implementations, the module includes a laterally contiguous lens array combined with a laterally non-contiguous array of lenses. For example, in some implementations, a laterally contiguous array of lenses includes multiple lenses formed together with a common body portion as a single injection molded monolithic piece; in other implementations, a laterally contiguous array of lenses includes multiple replicated lenses on a common transparent substrate, e.g. cover glass. In some cases, a laterally non-contiguous array of lenses includes individual injection molded lenses that are separate from other lenses in the same non-contiguous array. In other cases, the laterally non-contiguous array of lenses includes lenses replicated, respectively, on individual transparent substrates that are laterally separated from one another. Further, in some cases, the beam shaping elements in a particular array (contiguous or non-contiguous) are substantially co-planar with other beam shaping elements in the same array. In other cases, the beam shaping elements in a particular array may not be substantially co-planar with other beam shaping elements in the same array. Although lenses are described as particular example of the beam shaping elements, some implementations include other types of beam shaping elements.
In another aspect, an optoelectronic module has three optical channels. The module includes an image sensor including light sensitive regions each of which is associated with a respective one of the optical channels. The module has a first contiguous 3×1 array of first beam shaping elements, each beam shaping element being disposed in a different respective one of the optical channels. The module also includes a second beam shaping element that is disposed in a middle one of the optical channels. Such an arrangement can be advantageous, for example, in a camera assembly that includes a high-resolution primary camera and two secondary cameras that provide additional information that can be used to generate a depth map.
Various implementations can provide one or more of the following advantages. For example, by forming the arrays that are closer to the bottom of the stack as monolithic pieces, the overall footprint of the package can be made smaller. To provide the strict alignment and manufacturing tolerances that may be needed for some applications, the arrays closer to the top of the stack can be composed of individual beam shaping elements that are separate from other beam shaping elements in the same array. In some cases, better alignment can be achieved. Although the lateral positions of the lenses within a given contiguous lens array are fixed, the lateral positions of the individual lenses are not fixed with respect to the other lenses on the same lateral array.
In another aspect, the arrays of beam shaping elements include various alignment features that facilitate alignment of the different arrays.
Various examples are described in greater detail below. Other aspects, features and advantages will be readily apparent from the following detailed description, the accompanying drawings and the claims.
The present disclosure describes optoelectronic modules (e.g., hybrid lens array packages) that include different types of beam shaping elements such as lenses or lens arrays. For example, in some implementations, a hybrid lens array package includes two or more arrays of beam shaping elements stacked one above another. Each array can include multiple beam shaping elements. In some cases, the beam shaping elements of each array are substantially co-planar with one another; however, in other instances, the beam shaping elements of at least one of the arrays may not be substantially co-planar with other beam shaping elements in the same array. The size of the arrays can depend on the application. Examples of the size of each array are 1×2, 2×1, 3×1, 2×2 and 4×4. Other implementations may use arrays of other sizes.
Examples of the beam shaping elements that form the arrays include, but are not limited to, various optical elements. The optical elements may be, for example, passive elements such as lenses (e.g., diffractive or refractive). Other types of lenses also may be used (e.g., photochromatic lenses, as well as other types of transformable or dynamic lenses). In some implementations, the beam shaping elements may include optical filters. The beam shaping elements for different arrays in the stack may differ from one another. Thus, although the examples discussed in detail below illustrate lenses as the beam shaping elements, other implementations may incorporate different types of beam shaping elements.
The module can have multiple optical channels, each of which includes at least one beam shaping element (e.g., lens) that is part of a contiguous array. Each optical channel is associated with a respective light sensitive region of the image sensor 12. Some or all of the channels also can include at least one beam shaping element (e.g., lens) that is not part of a laterally contiguous array. In some implementations, the hybrid lens array package includes a contiguous lens array combined with a laterally non-contiguous array of lenses. As explained in greater detail below, in some implementations, a contiguous array of lenses includes multiple lenses formed together with a common body portion as a single injection molded monolithic piece; in other implementations, a contiguous array of lenses includes multiple replicated lenses on a common transparent substrate. In some cases, a laterally non-contiguous array of lenses includes individual injection molded lenses that are laterally separated from other lenses in the same non-contiguous array. In other cases, the non-contiguous array of lenses includes lenses disposed, respectively, on individual transparent substrates that are separated from one another. As will be apparent from some of the examples described in greater detail below, in some instances, a beam shaping element that forms part of a laterally non-contiguous array of beam shaping elements may nevertheless be contiguous with one or more beam shaping elements in the same optical channel (i.e., along the same optical axis).
Further, in some cases, the beam shaping elements in a particular array (contiguous or non-contiguous) are substantially co-planar with other beam shaping elements in the same array. In other cases, the beam shaping elements in a particular array may not be substantially co-planar with other beam shaping elements in the same array. Particular examples of hybrid lens array packages are described in greater detail below.
A transparent substrate 18 is disposed over the sensor 12, which can be attached to the cover 18 by a spacer 16. The spacer 16 can be attached, for example, to an inactive part of the sensor 12. The spacer 16 thus vertically separates the substrate 18 from the substrate 14 and from the photosensitive areas of the image sensor 12. The substrate 18, which can be composed, for example, of a glass or polymer material, is transparent to the wavelength(s) of light that the sensor 12 is designed to detect (e.g., infra-red (IR) or visible (RGB)). In some cases, optical filters may be provided in one or more of the optical channels to allow only incoming light of specified wavelength(s) to pass. The filters can allow different channels to detect different respective wavelengths of light. In some implementations, the thickness of the substrate 18 may vary from one channel to the next so as to provide for focal length adjustment (e.g., correction) for some of the channels. Alternatively, as shown in
The lens arrays can be placed in a lens barrel assembly 21, which can be attached to the object-side of the substrate 18. In the illustrated example of
In some applications, image quality tends to be less sensitive to the dimensions and alignment of the lenses closer to the bottom of the lens stack (i.e., the lenses closer to the sensor 12). By forming the lens arrays that are closer to the bottom of the stack as monolithic pieces, the overall footprint of the package 10 can be made smaller, since adjacent lenses in the same array can be placed closer to one another. Thus, although such lens arrays may have relatively large manufacturing tolerances and/or less than optimal alignment, it can be advantageous to provide monolithic arrays at the bottom of the lens stack. On the other hand, to provide the strict alignment and manufacturing tolerances that may be needed for some applications, the arrays closer to the top of the stack can be composed of individual lenses 28 that are laterally separate from other lenses in the same lateral array. Better alignment can be achieved because, although the lateral position of the lenses within the same monolithic lens array is fixed, the lateral position of the single lenses are not fixed with respect to the other lenses in the same lateral array. The stack thus can include two or more lens arrays, at least one of which is a laterally contiguous array formed, for example, as a monolithic piece and at least one of which is composed of one or more lenses that are not part of a laterally contiguous array. Preferably, the stack includes at least three lens arrays stacked one above the other.
As illustrated in the example of
As further shown in the example of
The spacer 16 and sides of the lens barrel assembly 21 can serve as walls of the package 10. In some implementations, the spacer 16 and lens barrel assembly 21 are composed, respectively, of materials that are substantially opaque to wavelengths of light detectable by the photosensitive regions of the sensor 12. For example, the spacer 16 and/or lens barrel assembly 21 can be composed of polymer materials (e.g., epoxy, acrylate, polyurethane, or silicone) containing a non-transparent filler (e.g., carbon black, pigment, or dye). In some implementations, sidewalls 19 of the substrate 18 also can be coated with a material that is substantially opaque to wavelengths of light detectable by the photosensitive regions of the sensor 12. Such features can help reduce the impact of stray light.
The exterior surface of the support substrate 14 can include one or more conductive contacts, which can be coupled electrically to the sensor 12, for example, by way of conductive vias extending through the substrate.
In some implementations, the lens barrel assembly is composed of a single unitary lens barrel 21A, as shown in
In other implementations, instead of a single unitary lens barrel, multiple lens barrels are used for different sub-groups of the lenses. As shown in the example of
Although the implementation of
In some instances, it may be desirable to add a thin coating 32 of a substantially opaque material on portions of some or all of the lenses 24, 28 and/or the monolithic pieces 22A, 22B that form the lens arrays (see
The shape of the individual lenses 24 or 28, when viewed from the object-side of the assembly, may be circular. In other implementations, however, different shapes may be used. For example, it may be desirable for at least one side edge of each of the lenses 24 or 28 to be flat, rather than rounded. For example, some or all of the individual lenses 24, 28 may have a plurality of flat side edges (e.g., a square or rectangular shape). In particular, it may be desirable for the lenses 24, 28 to have a substantially square shape, which can help reduce the overall footprint of the package 10 even further.
As noted above, in some implementations, each laterally contiguous array of lenses can include multiple lenses positioned on a common transparent substrate, and the laterally non-contiguous array of lenses can include lenses positioned, respectively, on individual transparent substrates. The various lenses and lens arrays can be made, for example, as part of a wafer-level replication process. The replication process can include, for example, dispensing tiny micro droplets of liquid polymer onto a glass or other transparent wafer, embossing the polymer with a customized mold, and curing the polymer on the wafer using ultraviolet light to harden it. In this context, a wafer refers to a substantially disk- or plate-like shaped item, its extension in one direction (y-direction or vertical direction) is small with respect to its extension in the other two directions (x- and z- or lateral directions). In some implementations, the diameter of a wafer is between 5 cm and 40 cm, and can be, for example, between 10 cm and 31 cm. The wafer may be cylindrical with a diameter, for example, of 2, 4, 6, 8, or 12 inches, one inch being about 2.54 cm. After replicating the lenses on the wafer, the wafer can be separated (e.g., by dicing) into individual lenses (each of which is on a piece of the wafer (i.e., a substrate)) and/or into contiguous lens arrays (each of which includes multiple lenses on a common piece of the wafer (i.e., a common substrate)).
Before separating the transparent wafer into individual lenses or laterally contiguous lens arrays, spacer wafers can be attached to one, or both, sides of the wafer(s). The spacer wafers provide spacers that facilitate attaching the transparent substrates to one another to form the vertical stack of lens arrays. The spacers can help ensure that there is a well-defined separation between the lens arrays. The spacer wafers can be composed, for example, of a material that is substantially opaque to wavelengths of light detectable by the photosensitive regions of the sensor. Thus, in some cases, the spacer is composed of polymer materials (e.g., epoxy, acrylate, polyurethane, or silicone) containing a non-transparent filler (e.g., carbon black, pigment, or dye).
In addition to the contiguous arrays of lenses,
Various modifications are possible. For example, in some instances, an inner partition portion 117 may be provided on the sensor-side of the transparent substrate 126B and/or may be provided on either one or both sides of the transparent substrate 126A. Likewise, the presence or location of the spacers may differ in some implementations. For example, spacers 116A or 116B may be omitted in some cases. Similarly, instead of providing the spacer 116D on the object-side of the transparent substrate 126B, spacers may be provided on the sensor-side of the transparent substrate 126C. Further, in some instances, spacers 116E may be placed on the sensor-side of the transparent substrate 126D. Other modifications are possible as well.
The transparent substrate 126A, 126B, 126C, 126D of
As noted above, in some instances, a beam shaping element that forms part of a laterally non-contiguous array of beam shaping elements may nevertheless be contiguous with one or more beam shaping elements in the same optical channel (i.e., along the same optical axis). Thus, for example, the lenses on the object-side of the substrates 126D in
In the illustrated example of
Each of the foregoing illustrated examples includes more than one contiguous array of lenses, where the contiguous arrays in a particular package are of the same type (e.g., injected molded monolithic pieces that include lenses, or lenses replicated onto a common cover). Some implementations, however, may include different types of contiguous lens arrays in the same package. For example, as shown in
In the foregoing examples (e.g.,
For example, as illustrated in
Further, in some instances, a particular contiguous array of beam shaping elements may include a respective beam shaping element for only some, but fewer than all, of the optical channels. An example is illustrated in
In some implementations, the arrays of beam shaping elements include various alignment features that facilitate alignment of the different arrays with one another. Such alignment features can be readily incorporated, for example, into injection molded arrays of lenses or other beam shaping elements.
A cross-sectional view of an example contiguous array 1000 of beam shaping elements 1002a-c is shown in
In some implementations, array 1000 may exhibit dimensional variations. For example, as shown in
A cross-sectional view of array 1100 is shown in
As described above, a laterally contiguous array of lenses can be stacked with another array of lenses (e.g., another laterally contiguous array of lenses or an array of individually formed lenses), such that an optical channel is formed by each stack of aligned lenses. As also described above, in some cases, dimensional variation might be greater in laterally contiguous lens arrays (e.g., a lens array formed as a monolithic piece) compared to arrays of individually formed, laterally non-contiguous lenses. Accordingly, laterally contiguous lens arrays and array of individually formed, laterally non-contiguous lenses can be stacked in particular combinations and positions in order to compensate for these dimensions variations without resulting in appreciable degradation of optical performance.
When two or more arrays of lenses (e.g., arrays 1100 and 1200) are stacked one over the other, the alignment guides of each array (e.g., alignment guides 1110a-d and 1208a-d) can provide alignment between the lenses of the different arrays, such that optical channels are formed by each stack of aligned lenses.
An example of this stacking is shown in
As shown in
The angles αa-d, βa-d, and γa-d can vary, depending on the implementation. In some implementations, angle αa-d is between approximately 0° to 90° (e.g., between 30° and) 60°. Angle βa-d is dependent on angle αa-d, and may be, for example, between 0° and 90° (e.g., between 30° and 60°). As an example, in some implementations, surfaces 1112a-d and 1210a-d can be configured to abut along a substantial portion of their respective lengths. Consequently, in some implementations, angle αa-d and angle βa-d may be equal (e.g., angle αa-d may be 60° and angle βa-d may be 60°). In some cases, angle αa-d and angle βa-d need not be exactly equal. For example, in some implementations, angle αa-d and angle βa-d can be approximately the same, such that the difference between the angles is within a particular acceptable range (e.g., within a range of 0-5°). As an example, in implementations where angle αa-d and angle βa-d are approximately the same, angle αa-d may be 60°, and angle βa-d may be 61°. The range of differences between approximately the same angles can differ, depending on the implementation. Angle γa-d can also vary, depending on the implementation. For example, angle γa-d may be an angle between 0° and 90°. In some implementations, angle γa-d depends on dimensional and optical requirements of the arrays and their lenses. For example, angle γ may be selected such that surfaces 1214a-d do not interfere with the optical performance of each of the lenses.
The width of recession cap surfaces 1120a-d and projection cap surfaces 1212a-d can also vary, depending on the implementation. In some implementations, recession cap surfaces 1120a-d and projection cap surfaces 1212a-d are substantially similar in width, such that appreciable misalignment of the lenses of arrays 1100 and 1200 within the plane normal to recession cap surfaces 1120a-d and projection cap surfaces 1212a-d is minimized. Peripheral surfaces 1118a-d provide mechanical stability for alignment guides 1110a-d, can be dimensioned accordingly.
Although the foregoing examples show a laterally contiguous array of lenses positioned on the sensor side of an array of individually formed, laterally non-contiguous lenses (e.g., the side facing an sensor of an imaging device), this need not be the case. For example, in some implementations, a laterally contiguous array can be stacked on the object side of an array of individually formed, laterally non-contiguous lenses. Further, although only two arrays of lenses are shown in the examples above, in some implementations, three or more arrays of lenses can be stacked together. For example,
Stacked arrays can be held together in various ways. For example, in some implementations, stacked arrays can be held together by the frictional and/or compressive forces between them (e.g., the frictional and/or compressive forces between their corresponding alignment guides). In some implementations, stacked arrays can be held together by an adhesive, either in addition to or instead of frictional and/or compressive forces. For example, an adhesive can be placed between each of the alignment guides of two arrays, such that they adhere to each other.
In some cases, when one array is inserted into the other, the alignment guides of one array are seated flush against the alignment guides of the other array (e.g., as illustrated in
In some implementations, the alignment guides of an array may be substantially rigid (e.g., cannot be readily deformed). In other implementations, the alignment guides of an array may deform under pressure. In these implementations, the angles of corresponding alignment guides do not need to be substantially similar. As an example,
In some implementations, if one or more of the alignment guides (e.g., alignment guides 1504a-b and 1522a-b) are deformable, when arrays 1500 and 1520 are pressed together, these deformable alignment guides can deform in order to provide flush seating between the opposing alignment guides. For example, if alignment guide 1504a is deformable, upon application of pressure, alignment guide 1504a might deform inwards towards optical axis 1508, increasing angle α such that it matches β. As a result of this deformation, flush seating is provided between alignment guides 1504a and 1522a. In some implementations, a deformable alignment guide can also be resilient, such that upon elastic deformation, an additional frictional or compressive force between two opposite alignment guides remains after pressure is released. Accordingly, the two stacked arrays may be more securely held together. As an example, referring to
Although alignment guides are shown as having projection and recession surfaces that are at oblique angles (e.g., acute or obtuse angles) relative to a lens' optical axis, this need not be the case. In some implementations, the projection and recession surfaces can be at substantially right angles relative to a lens' optical axis. For example,
In some of the examples above, stacked arrays are shown as having alignment guides that perfectly correspond with each other. For example, referring to
Implementations of the arrays described above provide for the stacking and alignment of a contiguous lens array with a single individual lens or an array of non-contiguous lenses. Implementations of these arrays may provide certain benefits. For example, some implementations allow for the combination of dimensionally non-critical contiguous lens arrays and dimensionally critical single lenses within the same lens-array stack. Further, the dimensionally non-critical contiguous lens array may define the lateral positions of each optical channel of a multi-optical-channel imager, while the single lenses, made to more exacting specifications, may dominate optical performance.
Various modifications may be made within the spirit of the invention. For example, the recession lens-stacking features may be incorporated into single lenses of a single lens array and corresponding projection lens-stacking features may be incorporated into a monolithic lens array. Other implementations may, for example, employ square single lenses, or lenses with at least one flat side, in a non-contiguous lens array, or employ square lenses, or lenses with at least one flat side, in a contiguous lens array, or combinations of square and round lenses.
Other implementations are within the scope of the claims.
Rudmann, Hartmut, Senn, Tobias, Engelhardt, Kai, Perez Calero, Daniel
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